Powder spray device and control method

Abstract

The electrostatic powder spraying device includes an air supply, a spray body, a voltage multiplier circuit, a sensor, and a controller. The air supply is configured to supply air having an input velocity. The spray body transmits a mixture of air and spray material along a flow path. The voltage multiplier circuit is configured to receive a voltage input and generate a power supply output that is supplied to electrodes disposed along the flow path, the power supply output having an output voltage and an output load current. The sensor is configured to detect at least one of the output voltage and the output load current. The controller is operatively connected to the sensor and the air supply. The controller is configured to control the air supply to adjust the input velocity of the air based on at least one of the output voltage and the output load current.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 330,664, filed April 13, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE This disclosure relates generally to electrostatic powder spraying devices, and more particularly to spraying devices and methods that automatically adjust spray rate to achieve a spray pattern. [Background technology]

[0003] Electrostatic spray guns are used in a variety of applications to spray liquid and / or powder paints onto a variety of moving or stationary objects and parts. Typically, paints are atomized and emitted as a cloud of droplets or powder particles from the end of the gun, which has a high voltage electrode. The electrode creates an electric field and an ion flux through which the particles to be sprayed pass, and the ion bombardment electrostatically charges the atomized paint particles passing through the ion-rich electric field. The electrostatically charged paint particles are then directed toward an electrically grounded object to be sprayed, which attracts the charged particles emitted from the end of the gun to the object, providing better adhesion and coverage of the object with the coating material. As used herein, "spray gun" includes any electrostatic spraying device, whether or not it is handheld and whether or not it is configured in a pistol shape.

[0004] Many handheld electrostatic spray guns utilize an internal high voltage power supply to the charging electrode. These spray guns have a low level voltage input, e.g., 12 volts DC to 30 volts DC, which is boosted by the gun's internal power supply to a desired level for the charging electrode, typically 50 kilovolts (KV) or higher. The low voltage level input allows the input power lines to the gun to be smaller, more flexible, and therefore more maneuverable, since no insulation is required for the lines to handle the high voltage levels. The internal power supply includes a voltage multiplier or circuit that boosts the low level supply voltage to a voltage level sufficient to electrostatically charge the spray particles. The multiplier circuit generally operates according to a characteristic power load line that describes the relationship between the voltage of the charging electrode and the amount of charge, e.g., current, delivered by the electrode(s).

[0005] The characteristic power load line of the spray gun's multiplication circuit determines the amount and distribution of charge delivered to the spray particles, and therefore controls the quality of the coating on the object being sprayed. Typically, the characteristic power load line of the gun's multiplication circuit is such that as the load current delivered to the spray particles increases, the output electrode voltage decreases, and the external impedance between the charged electrode and the ground reference decreases. The load line determines the rate at which the output voltage decreases with increasing load current. When the grounded article being sprayed approaches the tip of the spray gun electrode, such as when an object moving along a production line passes close to the gun electrode, or when the gun (and electrode) is actually operated close to the object and sprays into a recess or cavity in the object, the load current tends to increase, and as a result, the voltage at the electrode decreases. Regardless of how the load conditions change, the load current and output voltage generally vary during the spray application, affecting the amount of charge on the particle and the quality and efficiency of the paint application. Thus, the gun may operate in an optimal range along the power load line for some periods during a spray application, but at other times during the same spray application, operation may be less than optimal due to varying electrostatic conditions.

[0006] The foregoing background discussion is intended only to aid the reader in understanding the present invention and is not intended to limit the innovations described herein. Thus, the foregoing discussion should not be construed as indicating that certain elements of conventional systems are not suitable for use with the innovations described herein, nor is it intended that any element is essential to practicing the innovations described herein. Summary of the Invention

[0007] The aforementioned needs are substantially met by the electrostatic powder spraying device described herein.

[0008] One aspect of the disclosure provides an electrostatic material spraying device. The electrostatic material spraying device includes an air supply, a spray body, a voltage multiplier circuit, a sensor, and a controller. The air supply is configured to supply air having an input velocity. The spray body defines an atomizing flow path in fluid communication with the air supply and the atomizing material source. The atomizing flow path receives air from the air supply and atomizing material from the atomizing material source and transmits a mixture of air and atomizing material along the flow path. The voltage multiplier circuit is configured to receive a voltage input and generate a power supply output that is supplied to an electrode disposed along the flow path. The power supply output has an output voltage and an output load current. The sensor is configured to detect at least one of the output voltage and the output load current. The controller is operatively connected to the sensor and the air supply. The controller is configured to control the air supply to adjust the input velocity of air based on at least one of the output voltage and the output load current detected by the sensor. Controlling the amount of air affects the size and velocity of the spray pattern. Thus, the spray pattern can be optimized depending on the load conditions, particularly as influenced by the distance from the gun to the part. In some embodiments, such as Venturi application, the air supply may not be separate from the spray material supply. In some embodiments, such as dense phase systems, the air supply may be separate from the spray material supply. In embodiments, the spray material may be delivered to the sprayer by a pump, such as an ejector pump or a dense phase pump. In either pump type, the amount of air may be used to controllably deliver the spray material and shape the spray pattern. In dense phase systems, the patterning air may be provided to the gun spray body, spray nozzle, etc., providing a higher degree of pattern velocity control independent of the powder output.

[0009] Another aspect of the present disclosure provides a method of controlling the flow of material through an electrostatic powder spraying device. The electrostatic powder spraying device includes a spray body defining an atomizing flow passage having an outlet. The method includes flowing an input amount of air through the atomizing flow passage, flowing the atomizing material through the atomizing flow passage such that a mixture of air and atomizing material flows along the flow passage and through the outlet, generating a power supply output provided to an electrode, the power supply output having an output voltage and an output load current, the electrode being disposed within the flow passage of the mixture of air and atomizing material, detecting at least one of the output voltage and the output load current, and adjusting the input amount of air based on at least one of the output voltage and the output load current. In an aspect of the present disclosure, there is a relationship between the input air amount and the spray pattern speed. In an aspect of the present disclosure, the objective is to control the pattern speed and the pattern size. In this regard, a smaller amount of air through the nozzle may result in a softer and / or smaller spray pattern. Conversely, a larger amount of air through the nozzle may result in a harder and / or larger spray pattern.

[0010] Another aspect of the disclosure provides a control system for controlling air flow through an electrostatic powder spraying device. The electrostatic powder spraying device is configured to spray a mixture of air and spray material to paint a spray part. The electrostatic powder spraying device is further configured to provide a power supply output having an output voltage and an output load current to an electrode. The electrode is configured to provide an electric charge to the mixture of air and spray material. The control system includes a sensor and a controller. The sensor is configured to detect at least one of the output voltage and the output load current. The controller is operatively connected to the sensor and the air supply. The controller is configured to control the air supply to adjust an input rate of air provided by the air supply based on at least one of the output voltage and the output load current detected by the sensor. In an aspect, the disclosed method may control one or more of the flow of material, the flow of mixture, and / or the flow of air. In an aspect, the disclosed method operates to control an input air volume to generate a resultant output spray rate.

[0011] This Summary is provided to introduce some concepts in a simplified form that are further described in the Detailed Description section below. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Moreover, the claimed subject matter is not bound by limitations that solve any or all of the disadvantages noted in any part of this disclosure.

[0012] The foregoing summary, as well as the following detailed description of illustrative embodiments of the present application, will be better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the present application, illustrative embodiments of the present disclosure are shown in the drawings. It should be understood, however, that the present application is not limited to the precise arrangements and instrumentalities shown. [Brief description of the drawings]

[0013] [Figure 1]FIG. 1 shows a schematic of an electrostatic spray coating apparatus according to one aspect of the present disclosure. [Diagram 2] FIG. 2 illustrates a schematic of a voltage input circuit according to one aspect of the present disclosure. [Diagram 3] FIG. 2 illustrates an example of an operating load line for a multiplier circuit in voltage control mode, according to one aspect of the present disclosure. [Figure 4] FIG. 2 illustrates an example of an operating load line for a multiplier circuit in current control mode, according to one aspect of the present disclosure. [Diagram 5] 1 is a flow chart illustrating a method of controlling the flow of spray material through an electrostatic powder spraying device according to one aspect of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Certain terms used herein are for convenience only and are not limiting. The words "axial", "radial", "circumferential", "outward", "inward", "upper" and "lower" designate directions in the drawings to which reference is made. As used herein, the term "substantially" and its derivatives and words of similar meaning, when used to describe a size, shape, orientation, distance, spatial relationship, or other parameter, includes the stated size, shape, orientation, distance, spatial relationship, or other parameter, and can include ranges up to 10% greater and less than the stated parameter, including ranges greater and less than 5%, greater and less than 3%, greater and less than 1%, and less than 1%. The term "substantially" is intended to mean a substantial extent or a large portion, but not necessarily the entirety (but may include the entirety) of what is specified. All ranges disclosed herein are inclusive of the recited endpoints and are independently combinable (e.g., the range "2 grams to 10 grams" includes the endpoints of 2 grams and 10 grams, and all values ​​therebetween). The terminology includes the above-listed words, derivatives thereof, and similar meanings.

[0015] Successful powder coating of recessed areas, corners, and the like often depends on the ability to optimize electrostatic charge, powder output, and the aerodynamic properties of the spray pattern. The ability of the spray device to slow down the spray velocity as it approaches the part being sprayed (e.g., the sprayed part), or a portion of the sprayed part, can greatly improve powder deposition in difficult to coat areas. The spray devices described herein are configured to automatically vary the spray pattern velocity, powder output, or both, depending on the gun-to-part distance, independent of powder output.

[0016] Based on the change in voltage and / or current, the gun can be inferred to be closer to or farther from the painted product. In systems using dense phase pumps, the amount of air added to the spray system to create the desired spray pattern can be quickly and easily adjusted in response to the inferred change in the distance between the gun and the part. It will be appreciated that the ability to change the speed of the spray pattern is not limited to dense phase systems. A conventional Venturi pump can also automatically adjust the "atomizing" air to achieve similar results.

[0017] As an example, when painting electrical enclosures, more air and a faster spray pattern are beneficial for painting large flat surfaces. Also, when painting corners, it may be desirable to keep the powder output at a constant level while slowing the spray rate to reduce turbulence at the corners and improve powder deposition at the corners. This can be highly advantageous in both manual and automated applications. For example, when painting complex products using robots, when using multi-axis movers, or in manual applications, adjusting the air supplied to the spray gun based on the output voltage and / or output load current can improve powder deposition at the spray area.

[0018] FIG. 1 shows a schematic of an electrostatic spray coating system or electrostatic spray coating device 100 according to one embodiment of the disclosure. The embodiment shown in and described in connection with FIG. 1 can include, implement, utilize, etc., any other embodiment, component, feature, etc. of the disclosure described herein. The electrostatic spray coating device 100 can be utilized to spray a coating or spray material 103 on a part 101. The electrostatic spray coating device 100 can be hand-held and controlled by a user's motion, such as by a robotic arm or multi-axis mover, etc. In one embodiment, the electrostatic spray coating device 100 can be stationary. The electrostatic spray coating device 100 can include, for example, a dense phase system, a venturi pump system, or other coating system or coating device for coating a spray part with liquid paint and / or powder paint.

[0019] The electrostatic spray coating apparatus 100 may include a spray material source 102, an air source 104, a spray gun 106 having a charging electrode 108, and a gun control system 110. It will be appreciated that the charging electrode 108 may include one electrode or multiple electrodes. The electrostatic spray coating apparatus 100 may also include one or both of an external power source 112 and an internal power source 114. The charging electrode 108 of the spray gun 106 may be powered by at least one of the external power source 112 and the internal power source 114. For example, the electrostatic spray coating apparatus 100 may include a single one of the external power source 112 and the internal power source 114. The single power source may provide power to the electrode 108. Alternatively, the electrostatic spray coating apparatus 100 may include an external power source and an internal power source such that a portion of the power source is located both externally and internally to the electrostatic spray coating apparatus 100. The external power source 112 may be connected to the spray gun 106, for example, by a high voltage cable.

[0020] The spray material source 102 is connected to the spray gun 106 by, for example, a tube, hose, or other conduit 116. The spray material source 102 supplies the spray material 103 to the spray gun 106 to be applied to the part 101. The material may include, for example, a powder, a liquid, a mixture thereof, or even other materials for painting the part 101.

[0021] The air source 104 is connected to the spray gun 106 by, for example, a tube, hose, or other conduit 118. The air source 104 supplies air to the spray gun 106, which is mixed with the spray material from the spray material source 102 in an atomizing flow path 117 of the spray gun 106. The atomizing flow path 117 may be defined by a spray body 109 of the spray gun 106. The mixture of air and the spray material 103 is sprayed from the outlet 107 of the spray gun 106 onto the part 101 to apply paint to the part 101. As the mixture of air and the spray material 103 is sprayed by the spray gun 106, the air and the spray material 103 may come into electrical contact with the electrode 108, a corona associated with the electrode 108, an electric field due to the electrode 108, etc. To improve adhesion of the spray material 103 to the part 101, the part 101 may be grounded by connecting the part 101 to a ground G.

[0022] FIG. 2 shows a schematic of a voltage input circuit 200 according to one embodiment of the disclosure. The embodiment shown in and described in connection with FIG. 2 can include, implement, utilize, etc., any other embodiment, component, feature, etc. of the disclosure described herein. The voltage input circuit 200 can include a voltage input 202 and a voltage multiplier circuit 204. It will be understood that the voltage input circuit 200 can include fewer or more components. For example, the voltage input circuit 200 can include an operating circuit, a voltage limiting circuit, an oscillator, a sensor, or even other components. It will be understood that the external power source 112, the internal power source 114, or a combination of the external power source 112 and the internal power source 114 utilize the voltage input circuit 200 to provide charge to the electrode 108.

[0023] The voltage input circuit 200 outputs an input voltage V from a voltage input 202 to a voltage multiplier circuit 204. IN The voltage multiplier circuit 204 may include a transformer 206, a cascade 208, and a resistor 210. The voltage multiplier circuit 204 may provide an output voltage V OUT and the output load current I OUT The power supply generates a power output including:

[0024] A typical input voltage V from the voltage input circuit 200 IN The input voltage V may be in the range of 12 VDC to 30 VDC and is input to a transformer 206 and a cascade 208 which act as an input stage to the voltage multiplier circuit 204. The transformer 206 and the cascade 208 may step up the input voltage to a level acceptable to the voltage multiplier circuit 204 (e.g., a step-up transformer and a step-up cascade). The cascade 208 may include, for example, a diode bridge amplifier or the like. The voltage multiplier circuit 204 converts the input voltage V IN A high voltage output V generally ranges from 10 kilovolts (KV) to 150 kilovolts (KV). OUT The corresponding output load current I OUT The output voltage V of the voltage multiplier circuit 204 can be in the range of 1 μA to 150 μA. OUT is provided to a charging electrode 108. The charging electrode 108, which may be one or more high voltage charging electrodes, may be positioned proximate to the tip 105 of the spray gun 106 where it forms a corona and / or electric field 212. As atomized particles of the spray material 103 pass through the electric field 212, the atomized particles acquire an electrostatic charge. The charged particles are sprayed or conveyed toward the electrically grounded part 101, and as the charged particles pass near the part 101, the particles are attracted to the part 101. The charging of the spray material 103 promotes a uniform application of the material to the part 101. Atomization of the particles may be accomplished by any known method.

[0025] 3 illustrates an example graph 300 of an operating load line 301 of the voltage multiplier circuit 204 operating in a voltage limiting mode, according to one embodiment of the disclosure. The embodiment illustrated in and described in connection with FIG. 3 may include, implement, utilize, etc., any other embodiment, component, feature, etc. of the disclosure described herein. The voltage multiplier circuit 204 operates in a voltage limiting mode according to an embodiment of the disclosure. OUT and the output voltage level V OUT Typically, the output voltage V OUT and the load current I OUT There is a decreasing relationship between the load current I OUT As increases, the output voltage V OUT decreases. More specifically, the actual voltage at the charge electrode 108 decreases. In this regard, the controller 222 decreases the output voltage level V OUT Do not reduce the output voltage level V OUT indicates the voltage value. The operating load line 301 corresponds to a nearly constant 100% voltage output. In this regard, the voltage output may be set by the controller 222. As shown in FIG. 3, the load current I OUT An increase in may indicate a decrease in impedance between the gun and the part, corresponding to a closer gun-to-part distance. During operation of the voltage input circuit 200, the load current I OUT An increase in the load current I typically occurs when the tip 105 and charged electrode 108 of the spray gun 106 are moved closer to the grounded component 101 that is to be sprayed. For example, the spray gun 106 can be moved closer to the component 101 to spray a recess or depression in the component 101. This position closer to the component 101 therefore reduces the load current I OUT This results in an increase in

[0026] The input voltage V to the voltage multiplier circuit 204 IN may determine the operating load line 301 at which the voltage multiplier circuit 204 operates. The spray gun power supply operates at a constant input voltage V that is selected to provide an optimal operating load line 301 for the particular spray application in which the spray gun 106 is used. INThe operating load line 301 and thus the output voltage V OUT and the load current I OUT The relationship between is selected based on parameters such as the type of material being sprayed, e.g., powder or liquid type, the shape of the part 101 being sprayed, the desired coating speed, etc.

[0027] The operating load line 301 may extend from a “no load” or open circuit point to a maximum load or “short circuit” point, at which the output voltage V OUT However, the output voltage V required for the spray gun to properly deliver its charged spray coating is OUT and the load current I OUT The desired and / or target operating range of the output voltage V OUT is significantly lower than the maximum output voltage at the "no load" point and significantly higher than the minimum output voltage at the "short circuit" point.

[0028] 4 illustrates an example graph 420 of an operating load line 401 of the voltage multiplier circuit 204 operating in current-limited mode, according to one embodiment of the present disclosure. In current-limited mode, the load current I OUT is held constant, and the output voltage V OUT is adjusted to maintain the desired current level. As shown, the load current I OUT is held constant at 20 μA. The voltage change history can indicate a change in the distance between the gun and the part.

[0029] Output voltage V of the operating load line 301 OUT and the load current I OUT Based on the relationship between the output voltage V and the spray gun 106, in a typical spray device, moving the spray gun 106 closer to or farther from the part 101 will result in a larger output voltage V OUT and the load current I OUT For example, as shown in the exemplary graph 300, in voltage limit mode, at point A on the operating load line 301, the spray gun 106 may be spaced approximately 10 inches (250 mm) from the part 101. At point A, the load current IOUT At point B on the load line 301, the spray gun 106 can be spaced about 7 inches (178 mm) from the part 101. At point B, the load current I OUT At point C on the load line 301, the spray gun 106 can be spaced about 3 inches (76 mm) from the part 101. At point C, the load current I OUT is about 79 μA. It should be noted that in other embodiments, the voltage and current values ​​will be different. In this regard, various aspects of the present disclosure are applicable to those other embodiments as well. In a typical electrostatic spray device, the output voltage V along the operating load line 301 varies with the position of the spray gun 106 relative to the part 101. OUT and the load current I OUT Changes in can affect the electric field 212 generated by the electrode 108 and therefore affect the coating applied to the part 101.

[0030] In a voltage limiting mode (e.g., FIG. 3), the controller 222 regulates the output voltage V OUT To estimate the distance between the gun and the part, the load current I OUT For example, as the spray gun 106 gets closer to the part 101, the current increases, indicating to the controller 222 that the spray gun 106 is closer to the part 101. In the current limited mode (e.g., FIG. 4), the voltage fluctuations can be used to infer the distance between the gun and the part. For example, as the spray gun 106 gets closer to the part 101, the voltage decreases, indicating to the controller 222 that the spray gun 106 is closer to the part 101.

[0031] With reference to Figures 3 and 4 and their descriptions, it should be noted that aspects of the present disclosure are not limited to specific load lines such as the operating load line 301 shown in Figure 3 and the operating load line 401 shown in Figure 4. In this regard, aspects of the present disclosure may additionally be applied to implementations in which the shape of the load line may be changed. For example, the load line may be adapted for different applications and product types. Furthermore, aspects of the present disclosure are applicable to systems that may also implement changes in current limiting and changes in voltage regulation in response to changes in gun-to-part distance. In this regard, in all cases there is a relationship between voltage, current, and resistance (gun-to-part distance), and aspects of the present disclosure may be implemented to control either voltage or current and monitor changes in uncontrolled parameters in response to changes in gun-to-part distance.

[0032] 1 and 2, the gun control system 110 may be configured to adjust the flow rate of air supplied by the air supply 104 to increase / decrease the spray rate and cloud density of the air and material mixture sprayed on the part 101. The gun control system 110 is connected between the spray gun 106 and the air supply 104. As described further herein, based on parameters detected by the gun control system 110, the gun control system 110 may control, for example, the input rate of air supplied by the air supply 104. In one embodiment, the gun control system 110 may control the volume of coating material supplied by the spray material source 102 based on parameters detected by the gun control system 110. The input rate is determined by the output voltage V OUT and the load current I OUT may be controlled based on the position of the spray gun 106 relative to the part 101 to maintain at least one of the above within a desired and / or target range.

[0033] The gun control system 110 can include a sensor 220 and a controller 222. The sensor 220 detects the output voltage V supplied to the electrode 108 from the voltage multiplier circuit 204. OUT and the load current I OUTThe sensor 220 may include one or more sensors. For example, a single sensor may be configured to detect an output voltage V OUT and another sensor is configured to detect the load current I OUT It will be appreciated that the gun control system 110 may include other sensors configured to sense other parameters of the voltage input circuit 200. In one embodiment, the sensor 220 detects the output voltage V across the resistor 210. OUT and the load current I OUT The sensor 220 is configured to detect an output voltage V OUT and the load current I OUT , one or more signals indicative of the

[0034] The controller 222 controls the output voltage V OUT and the load current I OUT In this regard, the gun control system 110 and / or other components of the electrostatic spray coating apparatus 100 may include one or more conditioning circuits, analog-to-digital converters, filters, etc., that receive the signal. The controller 222 may be configured to receive the output voltage V OUT and the load current I OUT Record the received output voltage V OUT and the load current I OUT In one embodiment, the controller 222 may control the air supplied by the air supply 104 based on at least one of the output voltage V during operation of the spray gun 106. OUT and the load current I OUTat a desired level or within a desired and / or target range. In this regard, the gun control system 110 and / or other components of the electrostatic spray coating apparatus 100 may include one or more analog-to-digital converters, driver circuits, etc., that dynamically control the air supply 104. The controller 222 may be an electronic control unit, computing device, central processing unit, and / or other data manipulation device that may be used to facilitate control and regulation of any of the methods or procedures described herein. Although the controller 222 is depicted as a single unit, in other embodiments the controller 222 may be distributed as multiple separate but interoperating units, incorporated into other components, or located in different locations within or outside the electrostatic spray coating apparatus 100.

[0035] In one aspect, the controller 222 includes a processor 224, such as a microprocessor, microcontroller, etc., and a memory 226. The processor 224 may be operatively coupled to each of the sensors 220, the memory 226, the air source 104, etc. The processor 224 may be configured to receive and process signals from the sensors 220, the memory 226, and the air source 104, and store the signals in the memory 226.

[0036] The memory 226 may include random access memory (RAM), read only memory (ROM), or both. The memory 226 may store, for example, the output voltage V OUT and the load current I OUT The memory 226 may store desired and / or target values ​​or ranges for the air supply 104. The memory 226 may also store computer executable code including at least one algorithm for controlling the air supply to regulate the input rate or volumetric flow rate of air from the air supply 104.

[0037] The gun control system 110 may include fewer or more components to control the electrostatic spray coating equipment 100. For example, the gun control system 110 may include a communications interface to communicate with remote monitoring locations, disconnect switches, solenoids, drivers, transceivers, etc. to send and receive information and commands to facilitate control of the electrostatic spray coating equipment 100, a user interface to receive input from a user, or even other components.

[0038] Output voltage V OUT and the load current I OUT The desired and / or target values ​​or ranges for the output voltage V may be predetermined and stored in memory 226. Alternatively, the user may OUT and the load current I OUT The desired and / or target values ​​or ranges of the output voltage V may be input and stored in the memory 226. In one embodiment, the user may input and store the output voltage V OUT and the load current I OUT The user can adjust the desired and / or target value or range of the output voltage V to create the desired electric field 212. For example, depending on the spray material 103 and / or the part 101, a particular electric field 212 created by the electrode 108 may be desired to achieve an acceptable coating. OUT and the load current I OUT In operation, the gun control system 110 controls the output voltage V OUT and the load current I OUT The air supplied by air source 104 can be adjusted to create and maintain the desired electric field 212, such that at least one of the following is maintained at a desired and / or target value or within a desired and / or target range.

[0039] 5 shows a flow chart illustrating a method 400 of controlling the flow of spray material 103 through an electrostatic spray coating apparatus 100 according to one embodiment of the disclosure. The embodiment shown in and described in connection with FIG. 5 may include, implement, utilize, etc., any other embodiment, component, feature, etc. of the disclosure described herein. The steps illustrated in connection with method 400 may be performed in a different order, steps may be combined, additional steps may be included, and / or the like. Additionally, method 400 may be implemented as software by processor 224.

[0040] In step 402, the spray material 103 may be supplied from the spray material source 102 to the spray gun 106 via the conduit 116. The spray material 103 flows along a flow path 119 and passes into an atomizing flow path 117 of the spray gun 106. The spray material 103 may be supplied from the spray material source 102 at a substantially constant rate (e.g., a substantially constant flow rate, mass rate, flow velocity, etc.). The spray material 103 is mixed with air in the atomizing flow path 117.

[0041] In step 404, air is supplied from the air source 104 to the spray gun 106 via a conduit 118. The air flows into and through the spray passage 117 of the spray gun 106 along a flow path 119 (see FIG. 1). The air is mixed with the spray material 103 in the spray passage 117. The air source 104 flows air into the spray passage 117 at an input velocity. In this regard, the input velocity may have a direct or indirect correlation with the pressure supplied by the air source 104. In one embodiment, the controller 222 may pre-program an initial input velocity of air. The controller 222 may control the air source 104 to set the input velocity of air to the initial input velocity when the spray gun 106 is activated to spray. The air source 104 may be controlled by the controller 222 to supply air based on the velocity of the air, the volume of the air (e.g., volumetric flow rate), the pressure of the air, and / or other airflow parameters that control the flow of air, defined herein as airflow characteristics. In one embodiment, the air supply 104 can include a solenoid valve (not shown) that can be controlled by the controller 222 to regulate and control the input rate of the air.

[0042] The mixture of air and spray material 103 is flowed along a flow path 119 and is disposed in a charging region of the applicator to be charged by ion bombardment, and is disposed in electrical contact with the electrode 108, a corona associated with the electrode 108, an electric field with the electrode 108, or the like. The electrode 108 can be disposed along the flow path 119 adjacent the outlet 107 of the spray gun 106, either internal to the spray gun 106 (upstream from the outlet 107 of the spray gun 106 along the flow path 119) or external to the spray gun 106 (e.g., downstream from the outlet 107 of the spray gun 106 along the flow path 119). The mixture of air and spray material 103 flows through the outlet 107 of the spray gun 106 to the part 101.

[0043] In one embodiment, the air and atomized material 103 can be supplied together to the spray gun 106 (e.g., a venturi atomizer). For example, the air and atomized material 103 can be mixed before being supplied to the spray gun 106. Alternatively, the air and atomized material 103 can be supplied separately to the spray gun 106 (e.g., a high density atomizer). The air and atomized material 103 can be supplied separately to the spray gun 106 and mixed within the atomizing passage 117 of the spray gun 106.

[0044] In step 406, the voltage input 202 is the input voltage V IN is supplied to the multiplication circuit 204. The input voltage V IN is increased by the transformer 206 and the cascade 208. The increased input voltage V IN is provided through resistor 210.

[0045] It will be appreciated that steps 402, 404, and 406 can be performed substantially simultaneously. For example, when the electrostatic spray coating device 100 is turned on, air is supplied to the spray gun 106, the spray material 103 is supplied to the spray gun 106, and the input voltage V IN can be supplied to the voltage multiplier circuit 204 substantially simultaneously, thereby allowing the mixture of air and spray material 103 to be charged as soon as the mixture begins to flow through the outlet 107 of the spray gun 106.

[0046] In step 408, the voltage multiplier circuit 204 can generate a power supply output that is supplied to the electrode 108. The power supply output can have at least an output voltage V OUT and the load current I OUT The power supply output charges the electrode 108, which charges the mixture of air and spray material 103 that is sprayed onto the part 101.

[0047] In step 410, the sensor 220 detects the power output generated by the voltage multiplier circuit 204. For example, the sensor 220 detects the output voltage V OUT and the load current I OUTThe sensor 220 detects at least one of the output voltage V OUT and the load current I OUT The controller 222 can then transmit a signal indicative of the output voltage V OUT and the load current I OUT can be stored in memory 226.

[0048] In one embodiment, the sensor 220 detects an output voltage V across the resistor 210. OUT and the load current I OUT At least one of the output voltage V OUT and the load current I OUT may vary based on the position of the spray gun 106 relative to the part 101. For example, the resistance between the spray gun 106 and the part 101 increases as the spray gun 106 moves away from the part 101. Similarly, moving the spray gun 106 closer to the part 101 decreases the resistance between the spray gun 106 and the part 101. Based on the relationship between resistance, current, and voltage (e.g., Ohm's Law), the current between the spray gun 106 and the part 101 increases as the spray gun 106 moves closer to the part 101. Similarly, the current between the spray gun 106 and the part 101 decreases as the spray gun 106 moves away from the part 101. Additionally, the voltage drop across resistor 210 as the spray gun 106 moves closer to the part 101 is greater than the voltage drop across resistor 210 as the spray gun 106 moves away from the part 101. 3 shows the change in current and voltage drop based on the position of the spray gun 106 (see, for example, point A (10 inch spacing) and point C (3 inch spacing)). Thus, the distance between the spray gun 106 and the part 101 is related to the voltage drop and current flowing between the spray gun 106 and the part 101. The voltage drop and current flowing between the spray gun 106 and the part 101 is related to the output voltage V across resistor 210. OUT and the load current I OUT The estimation can be performed by detecting at least one of the following:

[0049] In step 412, the controller 222 detects the output voltage V OUT and the output load current I OUT The processor 224 adjusts the input rate of air provided by the air supply 104 based on at least one of the output voltage V OUT and the output load current I OUT at least one of the output voltages V OUT and the output load current I OUT Each output voltage V can be compared to a desired and / or target value or range. OUT and the output load current I OUT The desired and / or target value or range of may be related to the distance between the gun and the part. In one embodiment, during the voltage limit mode, the output load current I OUT is the output load current I OUT Based on the comparison, the controller 222 sends a signal to the air supply 104 to adjust the input speed. For example, the detected output load current I OUT is the output load current I OUT If the input air rate is greater than the desired and / or target value, the controller 222 can send a signal to the air source 104 to decrease the input air rate. By decreasing the input air rate, less mixture of air and sprayed material 103 flows through the spray gun 106, thereby resulting in a softer application of air and sprayed material 103 applied to the part 101 by the spray gun 106. The controller 222 can be configured to continuously or discretely send a signal to the air source 104 to decrease the input air rate until the desired and / or target rate is reached. The desired and / or target rate can be determined by a proportionality factor (Fp) of the output load current I. OUT and can be stored in the memory 226. Similarly, the detected output load current I OUT is the output load current I OUTis less than the desired and / or target value, the controller 222 can send a signal to the air source 104 to increase the input air rate to achieve the desired and / or target velocity. Increasing the input air rate increases the mixture of air and the atomized material 103 flowing through the spray gun 106, creating a better application. The controller 222 can be configured to continuously send a signal to the air source 104 to increase the input air rate until the rate reaches the desired and / or target value. In one embodiment, the controller 222 is configured to incrementally control the air source 104 to adjust the input air rate. In an embodiment, the controller 222 utilizes a look-up table, which can be stored in the memory 226, to determine the output voltage V OUT and the output load current I OUT In particular, the look-up table may control the air supply 104 based on at least one of the output voltage V OUT and the output load current I OUT In an embodiment, the controller 222 utilizes an algorithm, which may be stored in the memory 226, to determine the output voltage V OUT and the output load current I OUT In particular, the algorithm may control the air supply 104 based on at least one of the output voltage V OUT and the output load current I OUT In an embodiment, the controller 222 may associate a value for controlling the air supply 104 based on at least one of the output voltage V OUT and the output load current I OUT In particular, the artificial intelligence and / or machine learning may control the air supply 104 based on at least one of the output voltage V OUT and the output load current I OUT A value for controlling the air supply 104 based on at least one of

[0050] In one embodiment, the sensor 220 may be implemented as a distance sensor. The distance sensor may be configured to sense the distance between the spray gun 106 and the part 101. Based on the sensed distance between the spray gun 106 and the part 101, the controller 222 may control the input rate of air supplied by the air supply 104. For example, if the distance detected by the distance sensor is small, indicating that the spray gun 106 is close to the part 101, the controller 222 may decrease the input rate of air supplied by the air supply 104. If the distance detected by the distance sensor is large, indicating that the spray gun 106 is farther away from the part 101, the controller 222 may increase the input rate of air supplied by the air supply 104.

[0051] The controller 222 can dynamically control the air supply 104 to adjust the input rate of the air. As the spray gun 106 moves between positions closer to and further from the part 101, the controller 222 can send a signal to the air supply 104 to control the rate of the air. It will be appreciated that the controller 222 can control the air supply 104 to adjust the input rate of the air until a desired and / or target rate is reached, or until either a maximum or minimum input rate of air is achieved. For example, the air supply 104 can be configured to supply air from a minimum input rate to a maximum input rate. The minimum and maximum input rates can be a function of the air supply 104, the spray gun 106, a combination thereof, or even other functions. The minimum and maximum input rates can be stored in the memory 226 of the controller 222.

[0052] As can be appreciated by those skilled in the art, the illustrated structure of Figure 5 may be a logical and / or physical structure. Thus, the illustrated steps may be performed by employing various hardware components, software components, etc. In one aspect, one or more processes may be implemented as software, software program modules, etc.

[0053] Below are some non-limiting examples of aspects of the present disclosure. One example includes the following: Example 1. 1. An electrostatic material spraying apparatus comprising: an air supply configured to supply air having an input velocity; a spray body defining an atomizing flow path in fluid communication with the air supply and the atomizing material source, receiving air from the air supply and the atomizing material from the atomizing material source, and transmitting a mixture of air and atomizing material along the flow path; a voltage multiplier circuit configured to receive a voltage input and generate a power supply output supplied to electrodes disposed along the flow path, the power supply output having an output voltage and an output load current; a sensor configured to detect at least one of the output voltage and the output load current; and a controller operably connected to the sensor and the air supply and configured to control the air supply to adjust the input velocity of the air based on at least one of the output voltage and the output load current detected by the sensor.

[0054] The above examples may further include any one or a combination of two or more of the following examples. Example 2. The electrostatic material spraying apparatus of any example herein comprising a voltage input source configured to provide a voltage input to the voltage multiplier circuit. Example 3. The electrostatic material spraying apparatus of any example herein, wherein the voltage multiplication circuit includes a resistor, and the sensor is configured to detect at least one of the output voltage and the output load current through the resistor. Example 4. The electrostatic material spraying device of any example herein, wherein the sensor is configured to detect an output load current through the resistor, and the controller is configured to control the air supply to adjust an input rate of the air based on the output load current detected by the sensor. Example 5. The electrostatic material spraying device of any example herein, wherein the controller is further configured to compare the output load current with a target output load current, and if the output load current is greater than the target output load current, the controller controls the air source to reduce the input velocity of the air. Example 6. The electrostatic material spraying device of any example herein, wherein the voltage multiplication circuit includes a transformer configured to increase the voltage input. Example 7. Electrostatic material spraying device of any example herein including a powder source configured to supply a substantially constant flow rate of powder to the spraying channel. Example 8. The electrostatic material spraying device of any example herein, wherein the electrode is disposed within a flow path of the mixture of air and spray material. Example 9. The electrostatic material spraying device of any of the examples herein, wherein the electrode is disposed within the spray flow passage of the spray body.

[0055] One example includes the following: Example 10. A method for controlling a flow of material through an electrostatic powder spray device having a spray body defining an atomizing flow passage having an outlet, the method comprising: flowing air through the atomizing flow passage at an input velocity; flowing the atomizing material through the atomizing flow passage such that a mixture of the air and the atomizing material flows along the flow passage and through the outlet; generating a power supply output supplied to an electrode, the power supply output having an output voltage and an output load current, the electrode being positioned within the flow passage of the mixture of air and the atomizing material; detecting at least one of the output voltage and the output load current; and adjusting the input velocity of the air based on at least one of the output voltage and the output load current.

[0056] The above examples may further include any one or a combination of two or more of the following examples. Example 11. The method of any of the examples herein, wherein the power supply output is generated by a voltage multiplier circuit, the method including providing the voltage input to the voltage multiplier circuit. Example 12. The method of any of the examples herein, wherein the voltage multiplication circuit includes a resistor, and detecting at least one of the output voltage and the output load current includes detecting at least one of the output voltage and the output load current through the resistor. Example 13. The method of any of the examples herein, comprising comparing the output load current to a target output load current, and adjusting the air supply to decrease the input air rate if the output load current is greater than the target output load current, and adjusting the air supply to increase the input air rate if the output load current is less than the target output load current. Example 14. The method of any of the examples herein, wherein flowing the spray material through the spray passage comprises supplying a substantially constant flow rate of the spray material to the spray passage. Example 15. The method of any of the examples herein, wherein adjusting the input velocity of the air includes incrementally adjusting the input velocity of the air. Example 16. The method of any of the examples herein, wherein adjusting the input rate of air is performed by a controller, the controller configured to dynamically adjust the input rate of air while flowing air through the atomizing passage, while flowing the atomizing material through the atomizing passage, and while generating the power output.

[0057] One example includes the following: Example 17. A control system for controlling air flow through an electrostatic powder spraying device configured to spray a mixture of air and a spray material to paint a spray part, the electrostatic powder spraying device being further configured to supply a power supply output having an output voltage and an output load current to an electrode, the electrode being configured to supply an electric charge to the mixture of air and a spray material, the control system comprising: a sensor configured to detect at least one of the output voltage and the output load current; and a controller operably connected to the sensor and an air supply and configured to control the air supply to adjust an input rate of air supplied by the air supply based on at least one of the output voltage and the output load current detected by the sensor.

[0058] The above examples may further include any one or a combination of two or more of the following examples. Example 18. The control system of any of the examples herein, wherein the controller is further configured to compare the output load current to a target output load current, and if the output load current is greater than the target output load current, the controller controls the air supply to reduce the input rate of air. Example 19. The control system of any of the examples herein, wherein the controller is further configured to: if the output load current is less than the target output load current, the controller controls the air supply to increase the input velocity of the air.

[0059] One example includes the following: Example 20. An electrostatic material spraying device comprising: an air supply configured to supply air having airflow characteristics; a spray body defining an atomizing flow path in fluid communication with the air supply and the atomizing material supply, receiving air from the air supply and the atomizing material from the atomizing material supply, and transmitting a mixture of the air and the atomizing material along the flow path; a voltage multiplier circuit configured to receive a voltage input and generate a power supply output that is supplied to electrodes disposed along the flow path, the power supply output having an output voltage and an output load current; a sensor configured to detect at least one of the output voltage and the output load current; and a controller operably connected to the sensor and the air supply and configured to control the air supply to adjust the airflow characteristics of the air based on at least one of the output voltage and the output load current detected by the sensor.

[0060] The above examples may further include any one or a combination of two or more of the following examples. Example 21. The electrostatic material spraying apparatus of any example herein comprising a voltage input source configured to provide a voltage input to the voltage multiplier circuit. Example 22. The electrostatic material spraying apparatus of any example herein, wherein the voltage multiplication circuit includes a resistor, and the sensor is configured to detect at least one of the output voltage and the output load current through the resistor. Example 23. The electrostatic material spraying device of any example herein, wherein the sensor is configured to detect an output load current through the resistor, and the controller is configured to control the air supply to adjust an airflow characteristic of the air based on the output load current detected by the sensor. Example 24. The electrostatic material spraying device of any example herein, wherein the controller is further configured to compare the output load current with a target output load current, and when the output load current is greater than the target output load current, the controller controls the air supply to reduce an airflow characteristic of the air. Example 25. The electrostatic material spraying device of any example herein, wherein the voltage multiplication circuit includes a transformer configured to increase the voltage input. Example 26. Electrostatic material spraying apparatus of any example herein comprising a powder source configured to supply a substantially constant flow rate of powder to the spraying channel. Example 27. The electrostatic material spraying device of any example herein, wherein the electrode is disposed within a flow path of the mixture of air and spray material. Example 28. The electrostatic material spraying device of any of the examples herein, wherein the electrode is disposed within the spray flow passage of the spray body.

[0061] One example includes the following: Example 29. A method for controlling a flow of material through an electrostatic powder spray device having a spray body defining an atomizing flow passage having an outlet, the method comprising: flowing air having airflow characteristics through the atomizing flow passage; flowing the atomizing material through the atomizing flow passage such that a mixture of the air and the atomizing material flows along the flow passage and through the outlet; generating a power supply output supplied to an electrode, the power supply output having an output voltage and an output load current, the electrode being positioned within the flow passage of the mixture of air and the atomizing material; detecting at least one of the output voltage and the output load current; and adjusting the airflow characteristics of the air based on at least one of the output voltage and the output load current.

[0062] The above examples may further include any one or a combination of two or more of the following examples. Example 30. The method of any of the examples herein, wherein the power supply output is generated by a voltage multiplier circuit, the method including providing the voltage input to the voltage multiplier circuit. Example 31. The method of any of the examples herein, wherein the voltage multiplication circuit includes a resistor, and detecting at least one of the output voltage and the output load current includes detecting at least one of the output voltage and the output load current through the resistor. Example 32. The method of any of the examples herein, comprising comparing the output load current to a target output load current, and adjusting the air supply to decrease an airflow characteristic of the air if the output load current is greater than the target output load current, and adjusting the air supply to increase an airflow characteristic of the air if the output load current is less than the target output load current. Example 33. The method of any of the examples herein, wherein flowing the spray material through the spray passage comprises supplying a substantially constant flow rate of the spray material to the spray passage. Example 34. The method of any of the examples herein, wherein adjusting the airflow characteristics of the air includes incrementally adjusting the airflow characteristics of the air. Example 35. The method of any of the examples herein, wherein adjusting the airflow characteristics of the air is performed by a controller, the controller configured to dynamically adjust the airflow characteristics of the air while flowing the air through the atomizing flow passage, while flowing the atomizing material through the atomizing flow passage, and while generating the power output.

[0063] One example includes the following: Example 36. 1. A control system for controlling air flow through an electrostatic powder spraying device configured to spray a mixture of air and spray material to paint a spray part, the electrostatic powder spraying device further configured to supply a power supply output having an output voltage and an output load current to an electrode, the electrode being configured to supply an electric charge to the mixture of air and spray material, the control system comprising: a sensor configured to detect at least one of the output voltage and the output load current; and a controller operably connected to the sensor and an air supply and configured to control the air supply to adjust airflow characteristics of air supplied by the air supply based on at least one of the output voltage and the output load current detected by the sensor.

[0064] The above examples may further include any one or a combination of two or more of the following examples. Example 37. The control system of any of the examples herein, wherein the controller is further configured to compare the output load current to a target output load current, and if the output load current is greater than the target output load current, the controller controls the air supply to reduce the airflow characteristics of the air. Example 38. The control system of any of the examples herein, wherein the controller is further configured to: if the output load current is less than the target output load current, the controller controls the air supply to increase the airflow characteristic of the air.

[0065] The present disclosure may be implemented on any type of computing device having wired / wireless communication capabilities over a communication channel, such as, for example, a desktop computer, a personal computer, a laptop / mobile computer, a personal data assistant (PDA), a mobile phone, a tablet computer, a cloud computing device, etc.

[0066] Furthermore, in accordance with various aspects of the present disclosure, the methods described herein are intended to operate with dedicated hardware implementations, including, but not limited to, PCs, PDAs, semiconductors, application specific integrated circuits (ASICs), programmable logic arrays, cloud computing devices, and other hardware devices constructed to perform the methods described herein.

[0067] It should also be noted that the software implementation of the disclosure described herein is optionally stored on a tangible storage medium, such as a magnetic medium, such as a disk or tape, a magneto-optical or optical medium, such as a disk, or a solid-state medium, such as a memory card or other package containing one or more read-only (non-volatile) memories, random access memories, or other writable (volatile) memories. A digital file attached to an email or other self-contained information archive or collection of archives is considered a distribution medium equivalent to a tangible storage medium. Thus, the disclosure is considered to include the tangible storage or distribution media enumerated herein, including art-recognized equivalents and successor media, on which the software implementation herein may be stored.

[0068] Moreover, various aspects of the present disclosure may be implemented in non-general purpose computer implementations. Moreover, various aspects of the present disclosure described herein improve the functionality of the system as is evident from the present disclosure herein. Furthermore, various aspects of the present disclosure include computer hardware that is specially programmed to solve the complex problems addressed by the present disclosure. Thus, various aspects of the present disclosure improve the functionality of the system as a whole in specific implementations for carrying out the processes defined by the present disclosure and defined by the claims.

[0069] Artificial intelligence and / or machine learning may utilize any number of approaches, including one or more of cybernetics and brain simulation, symbolic, cognitive simulation, logic-based, anti-logic, knowledge-based, less-than-symbolic, embodied intelligence, computational intelligence and soft computing, machine learning and statistics, etc.

[0070] The electrostatic spray coating device 100 is versatile and operates on an input voltage V provided by a voltage input 202. IN 3, by dynamically controlling the input rate of air provided by air supply 104, without adjusting or changing either the output voltage VOUT and the load current I OUT can be controlled and maintained within desired and / or target levels or ranges.

[0071] It will be understood that the foregoing description provides examples of the disclosed systems and methods. However, it is contemplated that other implementations of the present disclosure may differ in detail from the foregoing examples. For example, any of the embodiments disclosed herein may incorporate features disclosed with respect to any of the other embodiments disclosed herein. All references to the present disclosure or its examples are intended to refer to the specific examples being discussed at the time, and are not intended to imply any limitations with respect to the scope of the present disclosure more generally. All distinctions and disparagement language regarding certain features is intended to indicate a lack of preference for those features, and is not intended to completely exclude such features from the scope of the present disclosure, unless otherwise specified.

[0072] As will be readily apparent to one skilled in the art, any now existing or later developed process, machine, manufacture, composition of matter, means, method, or step that performs substantially the same function or achieves substantially the same result as the corresponding embodiments described herein may be utilized in accordance with the present disclosure.

Claims

1. An air supply source configured to supply air having airflow characteristics, A spray body defines a spray channel that is in fluid communication with the air supply source and the spray material supply source, receives the air from the air supply source and the spray material from the spray material supply source, and transmits the mixture of the air and the spray material along the channel, A voltage multiplier circuit configured to receive a voltage input and generate a power output supplied to electrodes arranged along the flow path, wherein the power output has an output voltage and an output load current, A sensor configured to detect at least one of the output voltage and the output load current, A controller operably connected to the sensor and the air supply source, configured to control the air supply source to adjust the airflow characteristics of the air based on at least one of the output voltage and the output load current detected by the sensor, An electrostatic material spraying device equipped with the following features.

2. The electrostatic material spraying apparatus according to claim 1, further comprising a voltage input source configured to supply the voltage input to the voltage multiplication circuit.

3. The electrostatic material spraying apparatus according to claim 1, wherein the voltage multiplier circuit includes a resistor, and the sensor is configured to detect at least one of the output voltage and the output load current passing through the resistor.

4. The electrostatic material spraying apparatus according to claim 3, wherein the sensor is configured to detect the output load current passing through the resistor, and the controller is configured to control the air supply source to adjust the airflow characteristics of the air based on the output load current detected by the sensor.

5. The electrostatic material spraying apparatus according to claim 4, wherein the controller is further configured to compare the output load current with a target output load current, and if the output load current is greater than the target output load current, the controller controls the air supply source to reduce the airflow characteristics of the air.

6. The electrostatic material spraying apparatus according to claim 1, wherein the voltage multiplication circuit includes a transformer configured to increase the voltage input.

7. The electrostatic material spraying apparatus according to claim 1, further comprising a powder supply source configured to supply a substantially constant flow rate of powder to the spraying channel.

8. The electrostatic material spraying apparatus according to claim 1, wherein the electrode is disposed within the flow path of the mixture of the air and the spraying material.

9. The electrostatic material spraying apparatus according to claim 8, wherein the electrode is arranged in the spray channel of the spray body.

10. The electrostatic material spraying apparatus according to claim 1, wherein the airflow characteristics are one or more of the air velocity, the air volume, and the air pressure.

11. A method for controlling the flow of material through an electrostatic powder spraying apparatus, which includes a spray body that defines a spray path having an outlet, To flow air having airflow characteristics through the aforementioned spray channel, The mixture of air and spray material is flowed through the spray channel and through the outlet, The process involves generating a power output supplied to an electrode, wherein the power output has an output voltage and an output load current, and the electrode is positioned within the flow path of the mixture of the air and the atomizing material. To detect at least one of the output voltage and the output load current, Adjusting the airflow characteristics of the air based on at least one of the output voltage and the output load current, Methods that include...

12. The method according to claim 11, wherein the power output is generated by a voltage multiplier circuit, and the method further comprises supplying a voltage input to the voltage multiplier circuit.

13. The method according to claim 12, wherein the voltage multiplier circuit includes a resistor, and detecting at least one of the output voltage and the output load current includes detecting at least one of the output voltage and the output load current passing through the resistor.

14. The output load current is compared with the target output load current, If the output load current is greater than the target output load current, the air supply source is adjusted to reduce the airflow characteristics of the air. If the output load current is smaller than the target output load current, the air supply source is adjusted to increase the airflow characteristics of the air. The method according to claim 11, further comprising:

15. The method according to claim 11, wherein the flow of the spray material through the spray channel comprises supplying the spray material to the spray channel at a substantially constant flow rate.

16. The method according to claim 11, wherein adjusting the airflow characteristics of the air includes gradually adjusting the airflow characteristics of the air.

17. The method according to claim 11, wherein the adjustment of the airflow characteristics of the air is performed by a controller, the controller is configured to dynamically adjust the airflow characteristics of the air while the air is flowing through the spray channel, while the spray material is flowing through the spray channel, and while the power output is being generated.

18. The method according to claim 11, wherein the airflow characteristics are one or more of the air velocity, the air volume, and the air pressure.

19. A control system for controlling the airflow through an electrostatic powder spraying device, wherein the electrostatic powder spraying device is configured to spray a mixture of air and spray material to paint spray parts, and is further configured to supply a power output having an output voltage and an output load current to electrodes, the electrodes are configured to supply charge to the mixture of air and spray material, and the control system is A sensor configured to detect at least one of the output voltage and the output load current, A controller operably connected to the sensor and the air supply source, configured to control the air supply source to adjust the airflow characteristics of the air supplied by the air supply source based on at least one of the output voltage and the output load current detected by the sensor, A control system equipped with the following features.

20. The control system according to claim 19, wherein the controller is further configured to compare the output load current with a target output load current, and if the output load current is greater than the target output load current, the controller controls the air supply source to reduce the airflow characteristics of the air.

21. The control system according to claim 20, wherein the controller is further configured to control the air supply source to increase the airflow characteristics of the air when the output load current is less than the target output load current.

22. The control system according to claim 19, wherein the airflow characteristics are one or more of the air velocity, the air volume, and the air pressure.

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